Evaporator fan with shroud assembly

ABSTRACT

A shroud for mounting a fan is provided. The shroud may include a plate, a hub, a first leg, and a second leg. The plate may include an aperture edge of an aperture in a surface of the plate. The hub includes a bore defining an axis of rotation of a fan. The first leg and the second leg are mounted to and extend between the hub and the aperture edge. The first leg includes a first leg portion having a first curve shape in a plane perpendicular to the axis of rotation. The second leg may include a second leg portion having a second curve shape in the plane. The first curve shape may be an arc of a circle. A fan housing may include the shroud, an actuator to effect rotation of the fan, and a mounting bracket, which mounts the actuator to the shroud.

FIELD OF THE INVENTION

The subject of the disclosure relates generally to the field of fans.More specifically, the disclosure relates to a shroud assembly for afan.

BACKGROUND OF THE INVENTION

An evaporator fan assembly generally is provided in an evaporatorcompartment of a refrigerator or a freezer to circulate cooled airthrough the storage compartment. A typical evaporator fan assembly mayinclude a number of parts some or all of which may be fabricated ofmetal. The parts may include a shroud, a fan, a motor, and one or moremounting brackets and attachment parts for forming the fan assembly.Because refrigerator/freezers are generally located in a house or otherstructure, it is preferable that the noise level be minimized. To reducethe noise created by the fan assembly, each of the parts should beisolated from the others. Additionally, the greater the number of parts,the greater the potential for noise and the more time consuming theassembly process may be. Thus, there is a need for a fan assembly thatfurther reduces the noise level of the fan. There is further a need fora fan assembly that reduces the number of parts required, and therefore,the assembly time.

SUMMARY

Exemplary embodiments provide a fan assembly having a reduced noiselevel and a reduced assembly time. The fan assembly reduces the numberof parts in the assembly by manufacturing the shroud from plastic andintegrating a mounting bracket with the shroud thereby eliminating theneed to isolate the bracket from the shroud and eliminating a number ofthe grommets and screws necessary for attaching the fan assembly parts.

A shroud for mounting a fan includes, but is not limited to, a plate, ahub, a first leg, and a second leg. The plate may include an apertureedge of an aperture in a surface of the plate. The hub includes a boredefining an axis of rotation of a fan. The first leg mounts to andextends between the hub and the aperture edge. The first leg includes afirst leg portion having a first curve shape in a plane perpendicular tothe axis of rotation. The second leg mounts to and extends between thehub and the aperture edge.

A fan housing includes, but is not limited to, an actuator operablycoupled with a fan to effect rotation of the fan, a mounting bracket,and the shroud. The mounting bracket mounts the actuator to the shroud.

A fan assembly includes, but is not limited to, a fan including aplurality of blades, the actuator operably coupled with the fan toeffect rotation of the plurality of blades, the mounting bracket, andthe shroud.

A refrigerator includes, but is not limited to, a housing, the fan, theactuator, the mounting bracket, and the shroud. The housing includes aplurality of walls and a door. The plurality of walls and the doordefine an enclosed receptacle. The plate mounts to an interior surfaceof the enclosed receptacle.

Other principal features and advantages of the invention will becomeapparent to those skilled in the art upon review of the followingdrawings, the detailed description, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the invention will hereafter be described withreference to the accompanying drawings, wherein like numerals willdenote like elements.

FIG. 1 depicts a side perspective view of an evaporator fan assembly inaccordance with an exemplary embodiment.

FIG. 2 depicts an exploded view of the evaporator fan assembly of FIG. 1in accordance with an exemplary embodiment.

FIG. 3 depicts a side perspective view of a shroud of the evaporator fanassembly of FIG. 1 in accordance with an exemplary embodiment.

FIG. 4 depicts a top view of the shroud of FIG. 3 in accordance with anexemplary embodiment.

DETAILED DESCRIPTION

With reference to FIG. 1, a fan assembly 100 includes a mounting bracket102, an actuator housing 104, a fan mounting frame 106, a fan 108, and ashroud 110. Fan assembly 100 may be mounted for use within a variety ofdevices. In an exemplary embodiment, fan assembly 100 is mountedadjacent a heat exchanger to circulate heated/cooled air. For example,fan assembly 100 may be mounted adjacent an evaporator in a refrigeratorfor circulation of cooled air. As used in this disclosure, the term“mount” includes join, unite, connect, associate, insert, hang, hold,affix, attach, fasten, bind, paste, secure, bolt, screw, rivet, solder,weld, and other like terms.

With reference to FIG. 2, an exploded view of fan assembly 100 isprovided. Mounting bracket 102 may include a body 200, a first mountingarm 202, and a second mounting arm 204. First mounting arm 202 extendsfrom a first end of body 200. Second mounting arm 204 extends from asecond end of body 200 opposite the first end of body 200. Body 200includes a bracket aperture edge 206 which defines an aperture foraccepting an attachment mechanism such as a grommet or a nut. Firstmounting arm 202 may include a first clasp (not shown) extending from aside of first mounting arm 202. Second mounting arm 204 may include asecond clasp 208 extending from a side of second mounting arm 204.Second clasp 208 may include a receptacle for accepting a latch.

With reference to FIG. 2, actuator housing 104 may include an actuator(not shown), a first attachment mechanism 210, a port 212, a mountinglug 214, an actuator shaft 216, and a second attachment mechanism 218.Actuator housing 104 mounts between mounting bracket 102 and shroud 110.The actuator is housed within actuator housing 104. The actuator may beany device as known to those skilled in the art both now and in thefuture for causing movement of fan 108. Exemplary actuators include anelectric motor, a servo, stepper, or piezo motor, a pneumatic actuator,a gas motor, etc. Actuator housing 104 may have a variety of shapes andsizes to some extent dependent on the actuator selected. Firstattachment mechanism 210 may include a grommet or a nut as known tothose skilled in the art both now and in the future. First attachmentmechanism 210 isolates actuator housing 104 from mounting bracket 102and positions actuator housing 104 correctly relative to mountingbracket 102. Second attachment mechanism 218 may include a grommet or anut as known to those skilled in the art both now and in the future.Second attachment mechanism 218 isolates actuator housing 104 fromshroud 110 and positions actuator housing 104 correctly relative toshroud 110.

Port 212 may accept a cable connecting the actuator with a power supply,pneumatic supply, and/or a controller. In the exemplary embodiment ofFIG. 2, first attachment mechanism 210 fits over mounting lug 214. Firstattachment mechanism 210 mounts to bracket aperture edge 206 of mountingbracket 102 to mount actuator housing 104 to mounting bracket 102. Inthe exemplary embodiment of FIG. 2, actuator shaft 216 extends fromactuator housing 104 in a direction and from a side of actuator housing104 that is generally opposite mounting lug 214. Actuator shaft 216extends through second mounting mechanism 218. Actuator shaft 216includes a coupling end 220 that operably couples with fan 108.

With reference to FIG. 2, fan 108 may include a plurality of blades 222,a blade hub 223, and a shaft coupler 224. The plurality of blades 222extend radially outward from blade hub 223. The plurality of blades 222typically have an identical shape and are arranged symmetrically aboutblade hub 223. Shaft coupler 224 accepts coupling end 220 of actuatorhousing 104. The actuator effects rotation of actuator shaft 216.Through the coupling with shaft coupler 224, the rotational motion ofactuator shaft 216 effects rotation of the plurality of blades 222.Thus, actuator shaft 216 acts as a rotor of fan 108. Actuator shaft 216defines an axis of rotation A-A of the plurality of blades 222 of fan108. In the exemplary embodiment of FIG. 2, the axis of rotation A-Aextends through first and second attachment mechanisms 210, 218.

With reference to FIG. 2, fan mounting frame 106 may include a plate226, a first wall 228, and a second wall 230. Plate 226 has a generallyrectangular shape though other shapes, including square, circular,elliptical, polygonal, etc., and combinations of shapes may be usedwithout limitation. In the exemplary embodiment of FIG. 2, plate 226 issized and shaped to fit within an appropriately located space within arefrigerator or freezer to provide circulation of cooled air within therefrigerator or freezer. Plate 226 need not be a solid surface. Forexample, plate 226 may be formed of a mesh or a web of material. In theexemplary embodiment of FIG. 2, plate 226 extends in a plane that isgenerally perpendicular to axis A-A. First wall 228 and second wall 230extend from plate 226 at generally opposed edges. First wall 228 mayinclude a mounting aperture 229 in which an attachment mechanism such asa screw can be inserted for mounting fan mounting frame 106, forexample, within the refrigerator or freezer. Second wall 230 further mayinclude a mounting aperture (not shown).

Plate 226 further includes an aperture defined by an aperture edge 232.Aperture edge 232 may extend from an aperture wall 234 which extendsfrom a generally planar surface of plate 226. Aperture edge 232 forms agenerally circular shape though other shapes, including square,rectangular, elliptical, polygonal, etc., and combinations of shapes maybe used without limitation. In the exemplary embodiment of FIG. 2,aperture edge 232 is sized and shaped to accommodate the plurality ofblades 222 of fan 108 so that the plurality of blades 222 can rotatefreely within the aperture.

Shroud 110 provides the structural foundation for fan assembly 100 andmaintains the proper configuration between actuator housing 104 and fan108. With reference to FIG. 2, shroud 110 may include a plurality oflegs 236 and a hub 238. In the exemplary embodiment of FIG. 2, hub 238includes a bore through which axis A-A extends. Second attachmentmechanism 218 mounts to the bore of hub 238. The plurality of legs 236support hub 238 over the aperture defined by aperture edge 232 andaccommodate rotation of the plurality of blades 222 of fan 108.

With reference to FIG. 3, a perspective view of shroud 110 is providedwith additional detail. With reference to FIG. 4, a top view of shroud110 is provided. The plurality of legs 236 may include a first leg 300,a second leg 302, a third leg 304, and a fourth leg 306. First leg 300may include a first leg portion 308 and a second leg portion 310. Firstleg portion 308 of first leg 300 mounts to and extends from aperturewall 234. In the exemplary embodiment of FIG. 3, first leg portion 308of first leg 300 extends from aperture wall 234 in a direction that isgenerally perpendicular to plate 226 and parallel to axis A-A. In theexemplary embodiment of FIG. 3, second leg portion 310 of first leg 300extends from first leg portion 308 of first leg 300 at a first end andmounts to hub 238 at a second end opposite the first end.

Second leg 302 may include a first leg portion 312 and a second legportion 314. First leg portion 312 of second leg 302 mounts to andextends from aperture wall 234. In the exemplary embodiment of FIG. 3,first leg portion 312 of second leg 302 extends from aperture wall 234in a direction that is generally perpendicular to plate 226 and parallelto axis A-A. In the exemplary embodiment of FIG. 3, second leg portion314 of second leg 302 extends from first leg portion 312 of second leg302 at a first end and mounts to hub 238 at a second end opposite thefirst end.

Third leg 304 may include a first leg portion 316 and a second legportion 318. First leg portion 316 of third leg 304 mounts to andextends from aperture wall 234. In the exemplary embodiment of FIG. 3,first leg portion 316 of third leg 304 extends from aperture wall 234 ina direction that is generally perpendicular to plate 226 and parallel toaxis A-A. In the exemplary embodiment of FIG. 3, second leg portion 318of third leg 304 extends from first leg portion 316 of third leg 304 ata first end and mounts to hub 238 at a second end opposite the firstend.

Fourth leg 306 may include a first leg portion 320 and a second legportion 322. First leg portion 320 of fourth leg 306 mounts to andextends from aperture wall 234. In the exemplary embodiment of FIG. 3,first leg portion 320 of fourth leg 306 extends from aperture wall 234in a direction that is generally perpendicular to plate 226 and parallelto axis A-A. In the exemplary embodiment of FIG. 3, second leg portion322 of fourth leg 306 extends from first leg portion 320 of fourth leg306 at a first end and mounts to hub 238 at a second end opposite thefirst end.

In the exemplary embodiment of FIG. 3, second leg portion 310 of firstleg 300, second leg portion 314 of second leg 302, second leg portion318 of third leg 304, and second leg portion 322 of fourth leg 306generally extend in a plane perpendicular to axis A-A. As more clearlyshown with reference to FIG. 4, second leg portion 310 of first leg 300,second leg portion 314 of second leg 302, second leg portion 318 ofthird leg 304, and second leg portion 322 of fourth leg 306 definecurved shapes in the plane perpendicular to axis A-A. The view of FIG. 4is in the plane perpendicular to axis A-A. As a result, axis A-A extendsout of the page as shown in FIG. 4. With reference to FIG. 4, the curvedshapes of second leg portion 318 of third leg 304 and of second legportion 322 of fourth leg 306 may be arcs of a first circle 404.Similarly, the curved shapes of second leg portion 310 of first leg 300and of second leg portion 314 of second leg 302 may be arcs of a secondcircle (not shown). The center of first circle 404 may be locatedoutside of the aperture defined by aperture edge 232. The curved shapesof second leg portion 310 of first leg 300, of second leg portion 314 ofsecond leg 302, of second leg portion 318 of third leg 304, and/or ofsecond leg portion 322 of fourth leg 306 may be portions of a hyperbola,a parabola, an ellipse, a conic section, a quadratic curve, a free formcurve, or any other mathematical function that defines a curve. As usedin this disclosure, the term “curve” means a line or a surface thatbends in a smooth continuous fashion.

In the exemplary embodiment of FIG. 3, first leg 300 is a mirror imageof second leg 302 relative to a first plane parallel to axis A-A, andfirst leg 300 is a mirror image of fourth leg 306 relative to a secondplane parallel to axis A-A. Additionally, third leg 304 is a mirrorimage of second leg 302 relative to the second plane, and third leg 304is a mirror image of fourth leg 306 relative to the first plane.

Increasing the number of legs supporting the actuator reduces theperceived noise that is caused by the fan because the frequency of thenoise created by the fan is determined by the number of legs on theshroud. A larger number of legs creates a higher frequency noise whichis normally less noticeable to a consumer. By forming the legs withcurves in the plane perpendicular to the axis of rotation of theplurality of blades 222 of fan 108, the amount of noise created by thefan is also reduced relative to that created using a conventional designfor the legs.

In an exemplary embodiment, a first shroud leg may include first legportion 308 of first leg 300, second leg portion 310 of first leg 300,second leg portion 314 of second leg 302, and first leg portion 312 ofsecond leg 302 wherein second leg portion 310 of first leg 300 andsecond leg portion 314 of second leg 302 mount approximatelytangentially to hub 238. A second shroud leg may include first legportion 316 of third leg 304, second leg portion 318 of third leg 304,second leg portion 322 of fourth leg 306, and first leg portion 320 offourth leg 306 wherein second leg portion 318 of third leg 304 andsecond leg portion 322 of fourth leg 306 mount approximatelytangentially to hub 238. The first shroud leg may mount to hub 238 on afirst side and the second shroud leg may mount to hub 238 on a secondside, wherein the second side is generally opposite the first side.

In the exemplary embodiment of FIGS. 3 and 4, shroud 110 furtherincludes a first mounting brace 324 and a second mounting brace 340.First mounting brace 324 may include a first receptacle 326, a first arm332, a second arm 334, a third arm 336, a fourth arm 338, and a firstlatch 400 (shown with reference to FIG. 4). First receptacle 326 mayinclude a first end 328 and a second end 330 opposite first end 328.First end 328 of first receptacle 326 defines an aperture sized andshaped to accept first mounting arm 202. First mounting arm 202 may fitover an exterior of first end 328 of first receptacle 326 or may fitwithin an interior of first end 328 of first receptacle 326. First latch400 extends from a side of first receptacle 326 of first mounting brace324. In an exemplary embodiment, first latch 400 includes a recess. Asused in this disclosure, the term “recess” describes a variety ofstructural shapes including notch, cut, indentation, elbow, groove,corner, chamfer, slope, etc. that can provide a frictional or press fitwith an edge of an object to be engaged. The first clasp of firstmounting arm 202 engages with the recess of first latch 400 when firstmounting arm 202 is mounted to first mounting brace 324 thereby mountingactuator housing 104 to shroud 110.

First arm 332 and second arm 334 of first mounting brace 324 extendbetween second leg portion 310 of first leg 300 and second end 330 offirst receptacle 326 to support first receptacle 326. Third arm 336 andfourth arm 338 of first mounting brace 324 extend between second legportion 322 of fourth leg 306 and second end 330 of first receptacle 326to support first receptacle 326. Fewer or additional arms may be used tosupport first receptacle 326. In an alternative embodiment, second end330 mounts directly to second leg portion 310 of first leg 300 and tosecond leg portion 322 of fourth leg 306. In another alternativeembodiment, second end 330 of first receptacle 326 and/or first arm 332and/or second arm 334 of first mounting brace 324 mount to first legportion 308 of first leg 300. Similarly, second end 330 of firstreceptacle 326 and/or third arm 336 and/or fourth arm 338 of firstmounting brace 324 mount to first leg portion 320 of fourth leg 306.First arm 332, second arm 334, third arm 336, and fourth arm 338 offirst mounting brace 324 may define curved shapes in the planeperpendicular to axis A-A.

Second mounting brace 340 may include a second receptacle 342, a firstarm 348, a second arm 350, a third arm 352, a fourth arm 402 (shown withreference to FIG. 4), and a second latch 354. Second receptacle 342 mayinclude a first end 344 and a second end 346 opposite first end 344.First end 344 of second receptacle 342 defines an aperture sized andshaped to accept second mounting arm 204. Second mounting arm 204 mayfit over an exterior of first end 344 of second receptacle 342 or mayfit within an interior of first end 344 of second receptacle 342. Secondlatch 354 extends from a side of second receptacle 342 of secondmounting brace 340. In an exemplary embodiment, second latch 354includes a recess. Second clasp 208 of second mounting arm 204 engagesthe recess of second latch 354 when second mounting arm 204 is mountedto second mounting brace 340 thereby mounting actuator housing 104 toshroud 110.

First arm 348 and second arm 350 of second mounting brace 340 extendbetween second leg portion 314 of second leg 302 and second end 346 ofsecond receptacle 342 to support second receptacle 342. Third arm 352and fourth arm 402 of second mounting brace 340 extend between secondleg portion 318 of third leg 304 and second end 346 of second receptacle342 to support second receptacle 342. Fewer or additional arms may beused to support second receptacle 342. In an alternative embodiment,second end 346 of second receptacle 342 mounts directly to second legportion 314 of second leg 302 and to second leg portion 318 of third leg304. In another alternative embodiment, second end 346 of secondreceptacle 342 and/or first arm 348 and/or second arm 350 of secondmounting brace 340 mount to first leg portion 312 of second leg 302.Similarly, second end 346 of second receptacle 342 and/or third arm 352and/or fourth arm 402 of second mounting brace 340 mount to first legportion 316 of third leg 304. First arm 348, second arm 350, third arm352, and fourth arm 402 of second mounting brace 340 may define curvedshapes in the plane perpendicular to axis A-A.

Shroud 110 may be formed of plastic or of metal. In an exemplaryembodiment, shroud 110 and plate 226 are formed of a single piece ofmaterial. In another exemplary embodiment, shroud 110 and fan mountingframe 106 are formed of a single piece of material.

The foregoing description of exemplary embodiments of the invention havebeen presented for purposes of illustration and of description. It isnot intended to be exhaustive or to limit the invention to the preciseform disclosed, and modifications and variations are possible in lightof the above teachings or may be acquired from practice of theinvention. The embodiments were chosen and described in order to explainthe principles of the invention and as practical applications of theinvention to enable one skilled in the art to utilize the invention invarious embodiments and with various modifications as suited to theparticular use contemplated. It is intended that the scope of theinvention be defined by the claims appended hereto and theirequivalents.

1. A shroud for mounting a fan, the shroud comprising: a plate, theplate comprising an aperture edge of an aperture in a surface of theplate; a hub, wherein the hub includes a bore defining an axis ofrotation of a fan; a first leg mounted to and extending between the huband the aperture edge, wherein the first leg includes a first legportion having a first curve shape in a plane perpendicular to the axisof rotation; and a second leg mounted to and extending between the huband the aperture edge.
 2. The shroud of claim 1, wherein the first legmounts to the hub approximately tangentially.
 3. The shroud of claim 1,wherein the first leg mounts to the hub on a first side and furtherwherein the second leg mounts to the hub on a second side, the secondside opposite the first side.
 4. The shroud of claim 1, wherein thefirst leg includes a first end and a second end, and further wherein thefirst leg mounts to the aperture edge at the first end and at the secondend.
 5. The shroud of claim 1, wherein the second leg includes a secondleg portion having a second curve shape in the plane.
 6. The shroud ofclaim 5, further comprising: a third leg mounted to and extendingbetween the hub and the aperture edge, wherein the third leg includes athird leg portion having a third curve shape in the plane; and a fourthleg mounted to and extending between the hub and the aperture edge,wherein the fourth leg includes a fourth leg portion having a fourthcurve shape in the plane.
 7. The shroud of claim 6, wherein the firstleg includes a first end and a second end, and further wherein the firstleg mounts to the aperture edge at the first end and the first legmounts to the hub at the second end.
 8. The shroud of claim 1, furthercomprising a first mounting brace mounted between the first leg and thesecond leg, the first mounting brace including a first receptaclecapable of accepting a first mounting arm.
 9. The shroud of claim 8,further comprising a second mounting brace mounted between the first legand the second leg, the second mounting brace including a secondreceptacle capable of accepting a second mounting arm.
 10. The shroud ofclaim 8, further comprising a latch extending from a side of the firstmounting brace.
 11. The shroud of claim 10, wherein the latch extendsfrom a side of the first receptacle of the first mounting brace.
 12. Theshroud of claim 1, wherein the first curve shape is an arc.
 13. A fanhousing, the fan housing comprising: an actuator operably coupled with afan to effect rotation of the fan; a mounting bracket; and a shroud, themounting bracket mounting the actuator to the shroud, wherein the shroudcomprises a plate, the plate comprising an aperture edge of an aperturein a surface of the plate; a hub, wherein the hub includes a boredefining an axis of rotation of the fan; a first leg mounted to andextending between the hub and the aperture edge, wherein the first legincludes a first leg portion having a first curve shape in a planeperpendicular to the axis of rotation; and a second leg mounted to andextending between the hub and the aperture edge.
 14. The fan housing ofclaim 13, wherein the mounting bracket comprises a body and a firstmounting arm extending from the body, and further wherein the shroudfurther comprises a first mounting brace mounted between the first legand the second leg, the first mounting brace including a firstreceptacle capable of accepting the first mounting arm.
 15. The fanhousing of claim 14, wherein the mounting bracket further comprises asecond mounting arm extending from the body, and further wherein theshroud further comprises a second mounting brace mounted between thefirst leg and the second leg, the second mounting brace including asecond receptacle capable of accepting the second mounting arm.
 16. Thefan housing of claim 14, wherein the shroud further comprises a latchextending from a side of the first receptacle.
 17. The fan housing ofclaim 16, wherein the mounting bracket further comprises a claspextending from a side of the first mounting arm, and further wherein theclasp is capable of engaging the latch.
 18. The fan housing of claim 13,wherein the first curve shape is an arc.
 19. A fan assembly, the fanassembly comprising: a fan, the fan comprising a plurality of blades; anactuator operably coupled with the fan to effect rotation of theplurality of blades; a mounting bracket; and a shroud, the mountingbracket mounting the actuator to the shroud, wherein the shroudcomprises a plate, the plate comprising an aperture edge of an aperturein a surface of the plate; a hub, wherein the hub includes a boredefining an axis of rotation of the plurality of blades; a first legmounted to and extending between the hub and the aperture edge, whereinthe first leg includes a first leg portion having a first curve shape ina plane perpendicular to the axis of rotation; and a second leg mountedto and extending between the hub and the aperture edge.
 20. The fanassembly of claim 19, wherein the first curve shape is an arc.
 21. Arefrigerator, the refrigerator comprising: a housing, the housingincluding a plurality of walls and a door, the plurality of walls andthe door defining an enclosed receptacle; a fan, the fan comprising aplurality of blades; an actuator operably coupled with the fan to effectrotation of the plurality of blades; a mounting bracket; and a shroud,the mounting bracket mounting the actuator to the shroud, wherein theshroud comprises a plate, wherein the plate mounts to an interiorsurface of the enclosed receptacle, the plate comprising an apertureedge of an aperture in a surface of the plate; a hub, wherein the hubincludes a bore defining an axis of rotation of the plurality of blades;a first leg mounted to and extending between the hub and the apertureedge, wherein the first leg includes a first leg portion having a firstcurve shape in a plane perpendicular to the axis of rotation; and asecond leg mounted to and extending between the hub and the apertureedge.